Method and Apparatus of Optimizing the Cooling Load of an Economized Vapor Compression System

ABSTRACT

A vapor compression system includes a variable speed single stage compressor, a heat rejecting heat exchanger, an expansion device, and a heat accepting heat exchanger. The speed of the compressor is varied to control the refrigerant flow rate and match the cooling load requirements of the vapor compression system. A temperature sensor measures an air temperature in the refrigerated container. When the temperature sensor detects that the air temperature is above a threshold temperature, the microcontroller increases the speed of the compressor to increase the refrigerant flow rate and the cooling capacity of the vapor compression system. When the air temperature sensor detects that the air temperature is within a predetermined range from the set point temperature, the microcontroller sends a signal to slightly decrease the speed of the compressor, allowing fine adjustment of the cooling capacity of the vapor compression system to prevent overcooling of the refrigerated container.

BACKGROUND OF THE INVENTION

The present invention relates generally to a method of optimizing the cooling load of an economized vapor compression system by varying a speed of a single stage compressor.

A vapor compression system includes a compressor, a heat rejecting heat exchanger, an expansion device, and a heat accepting heat exchanger. Refrigerant circulates though the closed circuit system. The refrigerant exits the compressor through a discharge port at a high pressure and a high enthalpy. The refrigerant then flows through the heat rejecting heat exchanger at a high pressure and rejects heat to an external fluid medium. The refrigerant then flows through the expansion device, which expands the refrigerant to a low pressure. After expansion, the refrigerant flows through the heat accepting heat exchanger and absorbs heat from an air stream to cool a refrigerated container. The refrigerant then re-enters the compressor through a suction port, completing the cycle.

An economized cycle is commonly used to enhance performance and increase both capacity and efficiency of the vapor compression system. In an economized cycle, the refrigerant is split into two flow paths after exiting the heat rejecting heat exchanger. The refrigerant in an economizer flow path is expanded to an intermediate pressure and exchanges heat with the refrigerant in a main flow path in an economizer heat exchanger. The refrigerant in the economizer flow path is injected into an economizer port of the compressor. The refrigerant in the main flow path is expanded in the expansion device. By further cooling the refrigerant in the main flow path, the inlet enthalpy to the heat accepting heat exchanger decreases, increasing the cooling capacity of the vapor compression system.

Prior vapor compression systems employ a fixed speed multi-stage reciprocating compressor including at least two compression stages. Refrigerant is compressed in a first stage. The refrigerant in the economizer flow path is injected at an intermediate pressure between the first stage and a second stage. The refrigerant is then compressed in the second stage. A drawback to employing a multi-stage compressor is that it is expensive. Additionally, multi-stage compressors do not perform as well as single stage compressors in certain operating conditions. Finally, as the speed of the multi-stage compressor is fixed, the compressor is unable to be controlled to match the load requirements of the vapor compression system.

Hence, there is a need in the art for a method of optimizing the cooling load of an economized vapor compression system that overcomes the drawbacks and shortcomings of the prior art.

SUMMARY OF THE INVENTION

A vapor compression system includes a single stage compressor, a heat rejecting heat exchanger, an expansion device, and a heat accepting heat exchanger. Refrigerant circulates though the closed circuit vapor compression system. The refrigerant is compressed in the compressor and exits the compressor through a suction port. The refrigerant then enters the heat rejecting heat exchanger, such as a condenser or gas cooler, and rejects heat to an external fluid medium. The refrigerant then splits into a main flow path and an economizer flow path. Refrigerant in the economizer flow path is expanded to an intermediate pressure in an economizer expansion device and exchanges heat with the refrigerant in the main flow path in an economizer heat exchanger. The refrigerant in the economizer flow path is returned to the compressor through an economizer port. The refrigerant in the main flow path is expanded by the expansion device. After expansion, the refrigerant flows through the heat accepting heat exchanger and accepts heat from an air stream to cool a refrigerated container. The refrigerant then re-enters the compressor through a suction port, completing the cycle.

The speed of the compressor is varied to match the cooling load requirements of the vapor compression system. The compressor includes a motor that operates the compressor at a variable speed. By adjusting the speed of the compressor, the mass flow rate of the refrigerant through the vapor compression system can be controlled to efficiently cool the refrigerated container. Increasing the speed of the compressor increases the mass flow rate of the refrigerant and the capacity of the heat accepting heat exchanger to cool the refrigerated container. Decreasing the speed of the compressor decreases the mass flow rate of the refrigerant and the capacity of the heat accepting heat exchanger to cool the refrigerated container.

The vapor compression system includes an air temperature sensor that measures an air temperature in the refrigerated container. A desired set point temperature is programmed into a microcontroller. When the air temperature sensor detects that the air temperature is above a threshold temperature, the microcontroller increases the speed of the compressor to increase the mass flow rate of the refrigerant and therefore the cooling capacity of the vapor compression system.

When the air temperature sensor detects that the air temperature is within a predetermined range from the set point temperature, the microcontroller sends a signal to slightly decrease the speed of the compressor. This allows for fine adjustment of the cooling capacity of the vapor compression system to prevent overcooling of the refrigerated container. Once the air temperature sensor detects that the air temperature equals the set point temperature, the microcontroller sends a signal to slow down the motor of the compressor to maintain the set point temperature and match the cooling load of the vapor compression system.

These and other features of the present invention will be best understood from the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:

FIG. 1 schematically illustrates an economized vapor compression system of the present invention employing a variable speed single stage compressor;

FIG. 2A schematically illustrates the compressor when refrigerant enters a compression chamber through a suction port;

FIG. 2B schematically illustrates the compressor when refrigerant enters the compression chamber through an economizer port; and

FIG. 2C schematically illustrates the compressor when compressed refrigerant exits the compression chamber through a discharge port.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates an example vapor compression system 20 including a single stage compressor 22, a heat rejecting heat exchanger 24, an expansion device 26, and a heat accepting heat exchanger 28. Refrigerant circulates though the closed circuit vapor compression system 20. The refrigerant exits the compressor 22 through a discharge port 30 at a high pressure and a high enthalpy.

The refrigerant then flows through the heat rejecting heat exchanger 24, such as a condenser or gas cooler. An external fluid medium 32, such as water or air, flows through the heat rejecting heat exchanger 24 and exchanges heat with the refrigerant flowing through the heat rejecting heat exchanger 24. The refrigerant rejects heat to the external fluid medium 32 and exits the heat rejecting heat exchanger 24 at a relatively low enthalpy and a high pressure.

The refrigerant then splits into a main flow path 34 and an economizer flow path 36. Refrigerant in the economizer flow path 36 is expanded to an intermediate pressure in an economizer expansion device 38 and exchanges heat with the refrigerant in the main flow path 34 in an economizer heat exchanger 40, cooling the refrigerant in the main flow path 34. The refrigerant in the economizer flow path 36 flows along an economizer return path 42 and is injected into an economizer port 44 of the compressor 22 at an intermediate pressure between a suction pressure and a discharge pressure.

The refrigerant in the main flow path 34 is expanded by the expansion device 26, reducing the pressure of the refrigerant. The expansion device 26 can be a mechanical expansion device (TXV), an electronic expansion valve (EXV) or other type of known expansion device.

After expansion, the refrigerant flows through the heat accepting heat exchanger 28 and absorbs heat from an external air stream 46 to cool a space inside a refrigerated container 48. In one example, the refrigerated container 48 is used for shipping or transporting items which need to be cooled. For example, the refrigerated container 48 can be a cargo space or trailer of a vehicle, such as a truck. The refrigerant exits the heat accepting heat exchanger 28 at a relatively high enthalpy and a low pressure. The refrigerant then enters a suction port 50 of the compressor 22, completing the cycle.

As shown in FIG. 2A, the compressor 22 is a single stage compressor that includes at least one compression chamber 52. The compressor 22 can include a single compression chamber or multiple compression chambers. During a suction stroke of the compressor 22, the refrigerant from the heat accepting heat exchanger 28 enters the compressor chamber 52 through the suction port 50 at the suction pressure. A suction valve 54 allows the refrigerant to enter the compression chamber 52. A piston 56 blocks the economizer port 44 and prevents the refrigerant in the economizer return path 42 from entering the compression chamber 52 through the economizer port 44. A seal 64 between the piston 56 and the walls of the compression chamber 52 prevents refrigerant from flowing around the piston 56. As the refrigerant enters the compression chamber 52 through the suction port 50, the piston 56 moves in direction A away from the suction port 50, enlarging the compression chamber 52 to the position shown in FIG. 2B.

Towards the end of the suction stroke, the piston 56 no longer blocks the economizer port 44, allowing the refrigerant in the economizer return path 42 to enter the compressor chamber 52 through the economizer port 44. The intermediate pressure of the refrigerant entering the compression chamber 52 through the economizer port 44 causes the suction valve 54 to cover the suction port 50, preventing the refrigerant from the heat accepting heat exchanger 28 from entering the compression chamber 52 through the suction port 50.

As shown in FIG. 2C, during a discharge stroke, the piston 56 moves in direction B opposite to the direction A, compressing the refrigerant to the higher discharge pressure. The piston 56 blocks the economizer port 44 and prevents the refrigerant in the economizer return path 42 from entering the compression chamber 52 through the economizer port 44. The increase in pressure of the refrigerant opens a discharge valve 66, allowing the refrigerant to exit the compression chamber 52 through the discharge port 30 and flow to the heat rejecting heat exchanger 24.

The speed of the compressor 22 is varied to match the cooling load requirements of the vapor compression system 20. The compressor 22 includes a motor 60 that operates the compressor 22 at variable speeds. Preferably, the compressor 22 operates at at least two speeds. By adjusting the speed of the compressor 22, the mass flow rate of the refrigerant flowing through the vapor compression system 20 can be changed. Controlling the mass flow rate of the refrigerant through the vapor compression system 20 allows the load requirements of the vapor compression system 20 to be efficiently matched to optimally cool the refrigerated container 48. That is, by controlling the speed of the compressor 22, the load requirements of the vapor compression system 20 can be matched to optimally cool the refrigerated container 48.

Increasing the speed of the compressor 22 increases the mass flow rate of the refrigerant and the capacity of the heat accepting heat exchanger 28 to cool the refrigerated container 48. Decreasing the speed of the compressor 22 decreases the mass flow rate of the refrigerant and the capacity of the heat accepting heat exchanger 28 to cool the refrigerated container 48.

The vapor compression system 20 includes an air temperature sensor 58 that measures an air temperature representative of an air temperature in the refrigerated container 48. In one example, the temperature sensor 58 measures the air temperature of the air drawn from the refrigerated container 48. The air temperature sensor 58 communicates with a microcontroller 62. A desired set point temperature of the air in the refrigerated container 48 is programmed into the microcontroller 62.

When the air temperature sensor 58 detects that the air temperature is above a threshold temperature, the microcontroller 62 increases the speed of the compressor 22 to increase the mass flow rate of the refrigerant and therefore the cooling capacity of the vapor compression system 20. The microcontroller 62 runs an algorithm to determine the speed of the compressor 22 that matches the cooling load requirements of the vapor compression system 20.

Once the air temperature sensor 58 detects that the air temperature is within a predetermined range of the set point temperature, the microcontroller 62 slightly decreases the speed of the compressor 22. This reduces the mass flow rate of the refrigerant and the cooling capacity of the vapor compression system 20, allowing for fine adjustment of the cooling capacity of the vapor compression system 20 to prevent overcooling of the refrigerated container 48.

Once the air temperature sensor 58 detects that the air temperature equals the set point temperature, the microcontroller 62 sends a signal to slow down the motor 60 of the compressor 22 to reduce the mass flow rate of the refrigerant through the vapor compression system 20.

Fine adjustment of the cooling capacity of the vapor compression system 20 prevents overcooling of the refrigerated container 48 that would make the vapor compression system 20 inefficient. Once the motor 60 of the compressor 22 is slowed down, the heat accepting heat exchanger 28 continues to cool the refrigerated container 48 for a short period of time. If the compressor 22 continued to operate at the current speed with the current cooling capacity until the set point temperature was detected by the air temperature sensor 58, the heat accepting heat exchanger 28 would continue to cool the refrigerated container 48, and the temperature of the air in the refrigerated container 48 would drop below the set point temperature. This overcooling would make the vapor compression system 20 inefficient. By readjusting the speed on the compressor 22 when the air temperature is within the predetermined range, greater control of the cooling capacity of the vapor compression system 20 is possible. The compressor 22 can be unloaded in other ways, and one skilled in the art would know how to unload the compressor 22.

In one example, the set point temperature is 0° F. and the predetermined range is 10° F. If the air temperature sensor 58 detects that the air temperature increases above the threshold temperature, the microcontroller 62 increases the speed of the compressor 22 to increase the mass flow rate of the refrigerant and the cooling capacity of the vapor compression system 20. When the air temperature sensor 58 detects that the air temperature is 10° F. (within 10 degrees of the set point temperature of 0° F.), the microcontroller 62 decreases the speed of the compressor 22 and therefore the amount of cooling provided by the heat accepting heat exchanger 28. Once the air temperature sensor 58 detects that the air temperature is 0° F., the microcontroller 62 sends a signal to slow down the motor 60 of the compressor 22.

The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention. 

1. A vapor compression system comprising: a variable speed single stage compressor to compress a refrigerant to a high pressure; a heat accepting heat exchanger for exchanging heat between the refrigerant and an airflow to heat the refrigerant and cool the airflow, wherein the airflow is provided to an area; a temperature sensor to detect an air temperature of air in the area; and a controller that adjusts a speed of the variable speed single stage compressor based on the air temperature to match a cooling load requirement of the vapor compression system to cool the area.
 2. The system as recited in claim 1 further including a heat rejecting heat exchanger for cooling the refrigerant and a main expansion device to expand the refrigerant to a low pressure.
 3. The system as recited in claim 2 further including an economizer heat exchanger, wherein the refrigerant from the heat rejecting heat exchanger is split into an economized path which is reduced to an intermediate pressure in an economizer expansion device and a main path, wherein the refrigerant in the main path and the refrigerant in the economized path exchange heat therebetween in the economizer heat exchanger, and wherein the refrigerant in the economized path is injected into an economizer port of the variable speed single stage compressor and the refrigerant in the main path is expanded in the main expansion device.
 4. The system as recited in claim 3 wherein the variable speed single stage compressor includes a compression chamber and a piston that moves in the compression chamber, wherein the piston moves in a first direction to expand a volume of the compression chamber during a suction stroke and prevent the refrigerant in the economized path from entering the compression chamber and the piston moves in an opposing second direction to reduce the volume of the compression chamber during a discharge stroke to compress the refrigerant and prevent the refrigerant in the economized path from entering the compression chamber.
 5. The system as recited in claim 4 wherein the compression chamber is a single compression chamber.
 6. The system as recited in claim 1 further including a motor to control the speed of the variable speed single stage compressor and adjust a mass flow rate of the refrigerant through the vapor compression system.
 7. The system as recited in claim 1 wherein the controller increases the speed of the variable speed single stage compressor when the air temperature detected by the temperature sensor is greater than a threshold temperature programmed in the controller to reduce the air temperature to a set point temperature.
 8. The system as recited in claim 7 wherein the controller decreases the speed of the variable speed single stage compressor when the air temperature is less than a second threshold temperature programmed in the controller, and the second threshold temperature is greater than the set point temperature.
 9. The system as recited in claim 1 wherein the air temperature is a return air temperature of the air drawn from the refrigerated container.
 10. A vapor compression system comprising: a variable speed single stage compressor to compress a refrigerant to a high pressure; a motor to control a speed of the variable speed single stage compressor and adjust a mass flow rate of the refrigerant through the vapor compression system; a heat rejecting heat exchanger for cooling the refrigerant; a main expansion device to expand the refrigerant to a low pressure; an economizer heat exchanger, wherein the refrigerant from the heat rejecting heat exchanger is split into an economized path which is reduced to an intermediate pressure in an economizer expansion device and a main path, wherein the refrigerant in the main path and the refrigerant in the economized path exchange heat therebetween in the economizer heat exchanger, and wherein the refrigerant in the economized path is injected into an economizer port of the variable speed single stage compressor and the refrigerant in the main path is expanded in the main expansion device; a heat accepting heat exchanger for exchanging heat between the refrigerant and an airflow to heat the refrigerant and cool the airflow, wherein the airflow is provided to an area; a temperature sensor to detect an air temperature of air in the area; and a controller that adjusts the speed of the variable speed single stage compressor based on the air temperature to match a cooling load requirement of the vapor compression system to cool the area.
 11. The system as recited in claim 10 wherein the controller increases the speed of the variable speed single stage compressor when the air temperature detected by the temperature sensor is greater than a threshold temperature programmed in the controller to reduce the air temperature to a set point temperature.
 12. The system as recited in claim 11 wherein the controller decreases the speed of the variable speed single stage compressor when the air temperature is less than a second threshold temperature programmed in the controller, and the second threshold temperature is greater than the set point temperature.
 13. The system as recited in claim 10 wherein the variable speed single stage compressor includes a single compression chamber.
 14. A method of optimizing a cooling capacity of a vapor compression system comprising the steps of: compressing a refrigerant to a high pressure in a variable speed single stage compressor; heating the refrigerant in a heat accepting heat exchanger by accepting heat from an airflow to cool the airflow; providing the airflow to cool an area; detecting an air temperature of air in the area; and controlling a speed of the variable speed single stage compressor based on the air temperature to match a cooling load requirement of the vapor compression system to cool the area.
 15. The method as recited in claim 14 further including the steps of cooling the refrigerant in a heat rejecting heat exchanger and expanding the refrigerant to a low pressure in a main expansion device.
 16. The method as recited in claim 15 further including the steps of: splitting the refrigerant from the heat rejecting heat exchanger into an economized path and a main path; expanding the refrigerant in the economized path to an intermediate pressure in an economizer expansion device, exchanging heat between the refrigerant in the main path and the refrigerant in the economized path, injecting the refrigerant in the economized path into an economizer port of the variable speed single stage compressor, and expanding the refrigerant in the main path in the main expansion device.
 17. The method as recited in claim 14 further including the step of increasing the speed of the variable speed single stage compressor when the air temperature is greater than a threshold temperature to reduce the air temperature to a set point temperature.
 18. The method as recited in claim 17 further including the step of then decreasing the speed of the variable speed single stage compressor when the air temperature is less than a second threshold temperature, wherein the second threshold temperature is greater than the set point temperature. 